Project Overview
Throughout my time at university I was exposed to 3D printing, and as time went on it became more and more accessable, which ultimately led to the founding of Depth Design. We purchased a Makerbot Replicator 2 as it would allow us to print out prototypes and offer a 3D printing service.
Before buying this printer I was very interested in the Reprap project which focused on the design of 3D printers constructed from 3D printed and easily obtainable parts. As depth design had the means to build the necessary parts for a Reprap 3D printer we decided to give it a bash. We opted to build the "Foldarap" Reprap 3D printer. This printer was appealling because of it's solid structure and the fact it was portable due to its ability to fold.
The images and videos on this page show the goals of the project, process of building the 3D printer and the 3D printer in use (once it is up and running).
Project Goals
The main goal of the project is to have a fully functional printer capable of producing models of good and consistent quality, much like the printer shown in the video below.
A video of a foldarap in operation (this is the foldarap designers video, check out his youtube channel).
Other goals of the project include:
• Gaining a greater knowledge of how 3D printers work
• Learning the viability of making and selling these printers.
• Optimising our Makerbot Replicator 2's print settings whilst printing the Foldarap parts.
• Improving workshop skills such as electronics circuitry and part finishing.
Project Process
The first stage of the project was preparing all the aluminium sections which construct the frame. These were all cut by hand and then machined to length. The first 3D printed parts we would require were printed simultaneously.
The bottom frame of the Foldarap which consists of 7 aluminium sections, 4 printed corner parts along with T-nuts and screws to secure the parts together.
The process was much the same for the next parts which was the upright section of the printer, this would hold the components necessary to extrude the lastic filament and move the print head.
At this stage the frame was complete, the next step would be fully fitting the mechanical components such as lead screws, belts and bearings to the frame and then the hot end of the printer.
The hot end is a standard design used on many other reprap 3D printers. It basically consists of a section where filament is inserted, a heating block which melts the filament to a specific temperature (controlled by a thermistor), a nozzle where the heated filament is extruded, and a heatsink & fan which ensures that the heat from the heating block does not transfer to the area where the filament enters the assembly.
Assembled Hot End. The white tube at the top of the picture is where the filament enters and the nozzle under the brass nut at the bottom of the picture is where the heated filament is extruded.
The next step was fitting the hot end, lead screws for the Z axis and wiring all the components up to the circuit board.
Foldarap printer with all the motors and hot end wired up. The only components missing are the assembled print bed and a smaller power supply to fit under all the components.
